Pilot Plant Fabrication

We have extensive capabilities in designing, fabricating, and operating pilot plants for chemical, biochemical, and petroleum processes. We apply this knowledge and expertise to help our clients meet project requirements and accelerated timelines. Multifaceted resources are available across SwRI, and we have a long history of design, engineering, machining, and fabrication. SwRI pilot plants bridge the gap between lab experiments and commercial design in process scale-up.

Fabrication Strengths

• Modular pilot plant design and fabrication
• Manufacturing Accreditations
  • ISO 9001:2015
  • ISO 14001
  • ASME Code Section VIII – Pressure Vessels, Division 1–3
• Procurement
  • Established vendor contacts/relationships
  • Existing industry contacts for specialty design pieces/reactors
• Specialty coatings on- and off-site (metallics/composites)
• Custom materials/alloys (exotics/plastics)
• Certified welders
• Technicians with 30+ years of experience
• Rigging and large equipment installation experience

Commissioning and Operation Capabilities

• 24/7 pilot plant operations
• Experienced operators and engineers
• ISO 9001:2015 documentation and logbooks
• Documentation in accordance with PSM Plan

Engineering and Design Expertise

• Process design and simulation
• Computational fluid dynamics
• 3-D layout and plot plan
• Process flow diagram (PFD) development
• Piping and instrumentation diagram (P&ID) development
• Electrical drawings and design
• Equipment design, sizing, and procurement
• Vessel sizing and engineering drawings
• Materials compatibility testing
• Process control system development and installation
• HAZOP, PHA, and PSSR
• Final design package with complete bill of materials (BOM)

Facilities

• Fabrication high bays and pilot plant pad sites
• Utilities (natural gas, electrical power, air)
• Machine shops for fabrication and machining of custom equipment  to precise measurements
• 24/7 on-site security
• Site security at client offices available on request
• Shipping department for coordination of transportation, rigging, offloading, and containment of completed pilot plants
• Texas Commission on Environmental Quality blanket emissions permit for R&D

Industries

• Oil & Gas
• Polymers
• Chemicals
• Gas to Liquids
• Biofuels
• Environmental
• Demilitarization